Identity card

ABSTRACT

A card with a core and at least one chip incorporated into the core, characterised in that at least 5% of at least one main surface are covered by a seal, the chip is covered on both main surfaces with a seal or a plastics layer and a recess of the core and/or a seal exhibit fine structures, is distinguished by elevated anti-counterfeiting security and very good durability.

[0001] Card comprising a core and at least one chip incorporated intothe core and a process for the production thereof.

[0002] It is known to produce cards which contain an electronicallyreadable and/or writable chip. Such cards, also known as identity cards,are frequently printed, are used as payment or telephone cards and areusually produced from plastics such as for example PVC, PET or ABS. Thechip comprises a digital memory component, the storage capacity of whichmay vary, and which may be read and/or written either via contactsbrought out to the surface of the card or in contactless manner, forexample via a coil.

[0003] Chips which are suitable for both the contactless variant andthat comprising contacts are commercially available. However, cards madefrom plastics cannot be provided with high quality print and filmslaminated thereon can be exchanged without leaving visible traces. As aconsequence, known plastics cards may only insufficiently be protectedagainst tampering with the chip.

[0004] It is known from DE 42 18 158 to coat a plastics card withphotographic layers. However, the process required for this purpose, inwhich the photosensitive layers of a photographic material must bepeeled off from the support thereof, is highly complex.

[0005] A card is described as known in DE 29 20 012 which comprises aunit consisting of a chip with support element, supply lines andexternal contact surfaces, wherein the unit is rigidly connected withthe card. Due to the severe bending loads to which the unit is exposed,this structure is considered unsuitable for practical requirements.

[0006] The card according to the invention of DE 29 20 012 differs fromthe rigid structure in that the unit consisting of chip plus supportelement is accommodated in a cut-out which is somewhat larger than theunit and the unit is moreover retained in the cut-out by a resilientmaterial. The cut-out is intended to be similar in outline to thesupport element and is thus rectangular or round. Preferably, the chipplus support element and contact surfaces is held in the window by coverfilms laminated onto both sides, wherein the cover film must havepunched out portions over the contact surfaces. In order to avoiddamaging the chip, which, via the contact surfaces, is in direct thermalcontact with the cover films, only cold lamination can be used to applythe cover films. Films laminated in this manner may, however, be morereadily detached than hot-laminated films. In addition, according to DE29 20 012, the cover films must be stiff, so resulting in unpleasantlyrigid cards.

[0007] U.S. Pat. No. 4,457,798 discloses a process which involvestreating the card inlay at one point in such a manner that asubsequently hot-laminated film does not adhere at this point. Thispoint is then punched out in such a manner that the film remainsundamaged and the chip module is inserted and firmly adhered in theresultant indentation. While the process does indeed make it possible tohot-laminate films onto the card inlay, the chip and the contactsurfaces are, however, inadequately protected. In addition, residualrelease agent frequently results in detachment of the cover film and theprocess is highly elaborate.

[0008] The identity cards described in DE 30 299 39 contain an ICcomponent plus support element and connection lines, which component islaminated into the card composite and is bonded with the card on allsides and over its entire surface. In order to make it possible to usehot lamination for this purpose without destroying the chip, the lattermust be protected by buffer zones.

[0009] While the resultant identity cards do indeed exhibit resistantcover layers, anti-counterfeiting security is still unsatisfactory.

[0010] Known cards do not meet the elevated anti-counterfeiting securityrequirements of identity cards. For example, the cover films may tooeasily be removed without damaging the card body, so making it possibleto tamper with the chip and other security features and too fewdifferent security features are possible.

[0011] A further disadvantage of known cards is the inadequatedurability thereof, which results in detachment of the cover layer aftersome time, so in turn permitting tampering. In particular, it is then nolonger possible to tell whether the card has been tampered with or hassimply been exposed to particularly severe use.

[0012] Furthermore, prior art cards are very stiff, contacts brought tothe surface are readily worn away and manufacture is very elaborate andthus costly.

[0013] The object of the invention was accordingly to eliminate thestated disadvantages. Surprisingly, this is achieved with a card whichexhibits fine structures in a recess and/or the seal.

[0014] The invention accordingly provides a card with a core and atleast one chip incorporated into the core, characterised in that atleast 5% of at least one main surface are covered by a seal, the chip iscovered on both main surfaces with a seal or a plastics layer and arecess of the core and/or a seal exhibit fine structures.

[0015] A card should be taken to mean a three-dimensional article, inwhich two sides occupy a substantially larger area than the other sides.Examples of such cards are telephone cards, credit cards, parking cardsor identity cards. The two sides having the larger area are denoted themain sides or main surfaces of the card and the sides with the smallerareas the edges or margins. The dimensions of a card are rigidlystandardised for many applications and may otherwise be selected atwill. Although standardised cards are usually rectangular, they may alsobe of a different shape, such as for example square, round, hexagonaletc..

[0016] In a preferred embodiment of the invention, an image is arrangedon the core.

[0017] According to the invention, an image is any kind of reproduction,i.e. also of text and patterns. The reproduction may be coloured, black& white, invisible or a combination thereof. Invisible reproductions maybe rendered visible by infrared and/or UV light.

[0018] For the purposes of the invention, the core comprises anysufficiently strong material. The material may, for example, compriseplastics or paper, in particular high quality paper and particularlypreferably coated plastics or coated paper. The coating may be presenton one side or both sides and, in the case of coating on both sides, themain surfaces may mutually independently comprise one or more layers,which may also be different. A coating should be taken to mean one ormore layers.

[0019] The coating may either be applied directly, layer by layer, or acoated support, for example a coated film, may, however, also be appliedonto the plastic or the paper in order to produce the core.

[0020] Coating particularly preferably proceeds by the continuousflooding process, in which the layer or layers are poured as a solutionor dispersion, in particular as an aqueous solution, emulsion ordispersion, onto a support and then dried, wherein two or more layersare preferably applied in a one pass. In the case of flooding, inparticular for two or more layers, cascade and curtain coaters areparticularly suitable.

[0021] It is frequently preferred to provide the two main surfaces ofthe core with different coatings in order to be able to create a greaterdiversity of image information.

[0022] If particularly stringent requirements apply with regard to imagequality, a plastics-coated paper is preferred over pure paper, inparticular if it additionally comprises image-receiving and/orimage-forming layers.

[0023] In an advantageous embodiment, a paper coated on both sides withplastics is used and a plastics material which is particularly suitablefor this purpose is polyethylene.

[0024] The chip preferably comprises an integrated circuit on whichinformation can be stored digitally, wherein the data may particularlypreferably be read from and/or written to the chip in contactlessmanner. Among preferred contactless variants such as for exampleoptical, capacitive or inductive data transfer, it is the inductivelyoperated chips with a coil, in particular those known as “coil on chip”,in which the coil is arranged directly on the chip, which have provedparticularly advantageous for the cards according to the invention. Thischip has proved to be particularly stable in particular in the case ofhot lamination with plastics films. Suitable “coil on chip” products arefor example RFID chips from Maxell in which the antenna coil isintegrated on the chip.

[0025] The chip is located in a recess of the core, which recess iseither the same size as or larger than the chip to be inserted.

[0026] The higher the quality of the image optionally arranged on thecore, the more difficult it is unnoticeably to peel off a seal or aplastics layer applied thereon. Even if the core itself is not damaged,parts of the image remain stuck to the film and the card can no longerbe stuck back down unnoticeably.

[0027] In an advantageous embodiment, the core accordingly comprises onat least one main surface at least one image-receiving layer whichenables a particularly high quality image. Said layer preferablycomprises a non-swellable, microporous layer or a swellable, inparticular gelatine-containing layer, which is capable of particularlyreadily accepting ink, for example from inkjet printers. Preferredlayers are furthermore those which readily accept toner, for examplefrom laser printers. Other advantageous image-receiving layers are thosewhich particularly readily accept printing inks, for example those forscreen printing, offset printing, intaglio and flexographic printing,which are particularly good receiving layers for thermal sublimationprinting, thermal transfer printing or the silver salt diffusionprocess.

[0028] In a further advantageous embodiment, the core comprises on atleast one side at least one image-forming layer which contains aphotosensitive or heat-sensitive silver salt emulsion or precursorsubstances for the thermoautochrome process or microcapsules, forexample for cylithography. The layer preferably here comprises aphotographic layer which contains a photosensitive silver halideemulsion. In this case, when the card is being produced, thephotosensitive core is exposed with the image and processed in a mannercorresponding to its type to form a black & white or colour image. Inthe case of a photographic layer, the image can only be monochrome,while in the case of two or more layers yielding different colours,multicolour images are also possible.

[0029] The photosensitive or heat-sensitive silver salt emulsion, theprecursor substances for the thermoautochrome process or themicrocapsules may also be incorporated directly in the core, especiallyif the latter consists of paper.

[0030] The core used particularly preferably comprises a colourphotographic paper, in which the paper core, in particularplastics-coated on both sides, used to produce the card comprises atleast one blue-sensitive, yellow-coupling silver halide emulsion layer,at least one green-sensitive, magenta-coupling silver halide emulsionlayer and at least one red-sensitive, cyan-coupling silver halideemulsion layer and the finished card contains an image produced withthese photographic layers.

[0031] Particularly advantageous cards according to the inventioncontain, for example, cores which comprise photographic layers on bothsides, or which comprise a photographic layer on one main surface and animage-receiving layer on the other.

[0032] If only one of the main surfaces of the core is provided with aswellable, gelatine-containing, image-receiving or image-forming layer,it may be advantageous to apply onto the reverse side a “non-curling”layer which counteracts unwanted bending. Said layer may preferablycomprise an image-receiving gelatine-containing layer. The non-curlinglayer is particularly preferred for cores which are colourphotographically coated on one side, in particular for such paper cores.

[0033] It has proved advantageous to provide the card with at least oneantistatic layer, as read and write operations proceed substantiallymore reliably as a result. In unfavourable cases, the data on the chipor even the chip itself may be destroyed in the absence of an antistaticlayer. Suitable antistatic additives are described, for example, in partIX.C of Research Disclosure 38957, 1996.

[0034] Permanent, polythiophene-based antistatic layers, as are forexample described in EP 340 512, EP 440 957 and DE 4 211 459, areparticularly preferred.

[0035] In an advantageous embodiment of the invention, the core used toproduce the card permits a high-quality image with a resolution of atleast 6 lines per mm, in particular of 8 lines per mm.

[0036] If the high quality image is, for example a portrait photographof an individual, in particular a colour photograph, the card accordingto the invention is ideally suitable as an identity card.

[0037] The high quality image may also be located on a support which isapplied onto the core. It may here comprise, for example, a printed filmlaminated onto the core.

[0038] In a preferred embodiment of the invention, the high qualityimage is located directly on the core and/or in the image-forming orimage-receiving layer(s) thereof.

[0039] The seal may for example be colourless, coloured or printed, ispreferably thinner than the paper core and advantageously consists ofmaterials which can be processed to yield foils/films, such as forexample metals or plastics, wherein plastics and in particulartransparent materials are particularly advantageous. The seal itself mayalso contain security features, such as for example a hologram. Byappropriate selection of the material or the coating thereof, it ispossible to attenuate with the seal the sensitivity of the chip to datatransmitted in contactless manner, in order for example to preventunintentional addressing over long distances or due to interferencesignals. Plastics films with a vapour-deposited metal coating areparticularly suitable for this purpose. The seal may be bonded to thecore for example using cold or hot-melt adhesives, wherein pressure mayalso be applied. The seal is particularly preferably coated with ahot-melt adhesive and is bonded to the core with application of heat andpressure.

[0040] The seal preferably covers a security feature and/or the recessin which the chip is accommodated on at least one main surface andparticularly preferably on both main surfaces.

[0041] In this manner, the security feature and/or the chip may beprovided with particularly effective protection from tampering, inparticular if the adhesion between the layers of the card is selectedsuch that the adhesion between the seal and core is stronger than thecohesion within the core and/or stronger than the adhesion between thelayers of the core. In this manner, the core and in particular the imagearranged thereon is inevitably destroyed if the seal is removed.

[0042] A particularly advantageous seal is one which is at least 5% andin particular at least 40% smaller than the main surface of the card andwhich more preferably at no point on the main surface extends to theedge of the card. It consequently does not become detached so readilywhen exposed to flexural stress. In a particularly advantageousembodiment, the seal exhibits fine structures.

[0043] Particularly outstanding anti-counterfeiting security is achievedwith a card, the core of which contains at least one recess with finestructures, in particular if the recess is covered with the seal on atleast one side, still better on both sides. It is particularlyadvantageous here if the chip is accommodated in such a recess.

[0044] The fine structures in the core may, for example, be produced bypunching a correspondingly structured recess through the entire core.Preferably, however, the core consists of two or more plies of films,wherein one or more of these films comprise recesses with finestructures. In the case of such a layer structure of the core, the finestructures are particularly preferably arranged in the outer films. Thefine structures may be produced, instead of by punching, by any othermethod suitable for this purpose, for example also by cutting or bylaser.

[0045] The punched out portions for the chip, which are conventionallyadapted to the shape of the support element, i.e. are round orrectangular, do not ensure optimum protection from unauthorised peelingof the film. In contrast, in the case of punched out portions with finestructures, such peeling is immediately obvious as the structures areinevitably torn out.

[0046] In a further particularly advantageous embodiment of theinvention, both the seal and at least one recess in the card coreexhibit fine structures, wherein these elements in particular at leastpartially overlap.

[0047] Fine structures of the seal and the recess should be taken tomean, for example, “sawteeth” and/or narrow strips and/or smallpatterns, such as for example steps.

[0048] The sawteeth preferably have an acute angle of less than 90°, inparticular of less than 60° and particularly preferably of less than 40°and the strips and the small patterns preferably have a thickness ofless than 5 mm, in particular of less than 3 mm and particularlypreferably of less than 2 mm.

[0049] In an advantageous embodiment, the entire edge length of the sealand/or of the recess is at least 20%, preferably at least 50% andparticularly preferably at least 100% larger than in the case of acircular embodiment of identical area.

[0050] The seal and/or the recess is particularly preferably irregular,as a result of which it may act as a watermark if the card is held upagainst the light.

[0051] Further advantages with regard to the durability andanti-counterfeiting security of the card are obtained if the card iscovered on at least one main surface at least over its entire area witha plastics layer and in particular when it is covered on both mainsurfaces with a plastics layer which projects beyond all the card'sedges and these projecting margins of the two layers are weldedtogether.

[0052] The plastics layer covering the entire area is particularlyadvantageously arranged over a seal which is smaller than the mainsurface.

[0053] In a further advantageous embodiment, the seal and the plasticslayer covering the seal consist of different materials and/or the sealexhibits greater adhesion to the core than it does to the plastics layerarranged over the seal.

[0054] Both the seal and the plastics layers according to the inventionmay be provided with UV protection and comprise an image.

[0055] The cards according to the invention are preferably provided withfurther security features, such as for example a magnetic strip,signature strips, guilloche patterns, microprint, UV print, UV markers,holograms, kinegrams, laser images, watermarks, embossing, lasergravure, interference gratings, IR-readable symbols, thermochromefeatures, fluorescent pigments, release lacquers, predetermined breakingpoints and scoring in the plastics layers, the seal or the remainingsecurity features.

[0056] IR-readable symbols may be produced in a particularly simple andhigh quality manner by means of a photographic layer if processing iscontrolled in such a manner that not all the silver is bleached. Themetallic silver which remains in accordance with the image has very goodIR readability.

[0057] An interference grating, which is preferably similar to thatdescribed in DE 198 17 105, may preferably be arranged on the front andreverse sides of a seal, on two seals covering a recess, on a seal and aplastics layer located thereover or on the front and reverse sides of aplastics layer. Another preferred arrangement on the front and reversesides of the main surfaces is possible if a transparent material is usedas the core. If the grating is produced by photosensitive layers, thefront and reverse sides may be separately addressed in the case ofdifferent spectral sensitisation. The interference grating comprisesclosely spaced superimposed grids of lines or other fine patterns whichform a changing moiré pattern when the card is bent or flexed.

[0058] The release lacquers are capable of reducing the adhesion oflocalised areas of the main surface to the seal and/or a plastics layerand/or of reducing adhesion within the core in order to render uniformdetachment of seal and/or plastics layer still more difficult.

[0059] The invention also provides a process for the production of acard according to the invention, characterised in that a recess for thechip is created in the core, the chip is inserted once the recess hasbeen covered on one side with the seal and then the second side of therecess is covered with the seal or a plastics layer, wherein the recessand/or the seal exhibit fine structures.

[0060] In a preferred embodiment of the process, an image is produced onthe core.

[0061] Production of the image is adapted to the above-described corevariants according to the invention and may proceed, for example, bymeans of laser printers, inkjet printers, thermal sublimation printing,thermal printers or exposure with an image.

[0062] In addition to the advantages already described, the seal is alsohighly advantageous for the manufacturing process, in particular if itcovers less than 50% of the main surface and does not extend to the edgeof the card at any point. Since the smaller seal need not be exactlyflush with the edges of the card, it may be applied much more simply andrapidly. In addition, if it is coated with a suitable adhesive, the sealcan fix the chip and thus simplify subsequent manufacturing steps. Cardproduction may consequently be automated straightforwardly.

[0063] Further preferred embodiments of the invention are disclosed inthe claims.

1. A card with a core and at least one chip incorporated into the core,characterised in that at least 5% of at least one main surface iscovered by a seal, the chip is covered on both main surfaces with a sealor a plastics layer and a recess of the core and/or a seal exhibit finestructures.
 2. A card according to claim 1, characterised in that atleast one seal consists of plastics.
 3. A card according to one ofclaims 1 or 2, characterised in that the core comprises paper orplastics-coated paper.
 4. A card according to one of claims 1 to 3,characterised in that the core comprises at least one image-receivinglayer on at least one main surface.
 5. A card according to claim 4,characterised in that the image-receiving layer comprises a microporousor gelatine-containing layer.
 6. A card according to one of claims 1 to3, characterised in that the core comprises at least one image-forminglayer on at least one side.
 7. A card according to claim 6,characterised in that the image-forming layer comprises a photographiclayer.
 8. A card according to one of claims 1 to 7, characterised inthat an image is arranged on the core.
 9. A card according to one ofclaims 1 to 8, characterised in that it is provided on at least one mainsurface with a seal which is at least 5% smaller than the main surface.10. A card according to claim 9, characterised in that the seal extendsat no point to the edge of the card.
 11. A card according to one ofclaims 1 to 10, characterised in that at least one seal covers therecess for the chip on at least one side.
 12. A card according to one ofclaims 1 to 11, characterised in that the core contains at least onerecess with fine structures.
 13. A card according to claim 12,characterised in that the chip is accommodated in the recess.
 14. A cardaccording to one of claims 1 to 13, characterised in that at least oneseal comprises fine structures.
 15. A card according to one of claims 1to 14, characterised in that the card is covered on at least one mainsurface at least over its entire area with a plastics layer.
 16. A cardaccording to one of claims 1 to 15, characterised in that the card iscovered on both main surfaces with a plastics layer which projectsbeyond all the card's edges and the projecting margins of the two layersare welded together.
 17. A process for the production of a card with acore and at least one chip incorporated in the core, characterised inthat a recess for the chip is created in the core, the chip is insertedonce the recess has been covered on one side with a seal and then theopposite side of the recess is covered with a seal or a plastics layer,wherein a recess of the core and/or the seal exhibit fine structures.